Battery charger

ABSTRACT

A battery charger is provided on which power conversion components for converting commercial power to direct current (DC) power are mounted. The power conversion components include a power breaker for switching input alternate current (AC) power on/off, a power conversion circuit for converting the input AC power to a predetermined AC power, a voltage conversion circuit for converting the predetermined AC power to a predetermined voltage, and a rectifier circuit for converting the AC power that has been converted to the predetermined voltage to DC power. The power conversion components are mounted on a core frame, and an outer housing is mounted to the core frame in a manner so as to cover the core frame. The power breaker, the power conversion circuit, the rectifier circuit, and the voltage conversion circuit are mounted in this order to the core frame.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to Japanese Patent ApplicationNo. 2011-223286, filed Oct. 7, 2011 and incorporated herein in itsentirety.

TECHNICAL FIELD

The present invention relates to a battery charger preferably applied tocharging a battery loaded on an electric vehicle or a hybrid vehicle.

BACKGROUND

There is known a battery charger comprised of an electric circuitincluding a power-supply system for supplying electric power to a powersource battery on the interior of the back of an indicator window of itschassis and/or on the back of its operator's panel (see paragraph 0017and FIGS. 3 and 4 of Japanese Patent Application Laid-open No.H11-266509).

SUMMARY

In the charger device of the prior art, however, any consideration isnot given to lengths of cables among power conversion components.Therefore, if the lengths are not made equal when converting three-phasecurrent power into direct current power, imbalance in electricproperties of respective phases such as noise, inductance among thecables, and such possibly comes out and leads to reduction in efficiencyof power conversion.

A problem to be solved by the present invention is to provide a chargerdevice that can set lengths of cables among power conversion componentsas equal as possible so as to improve efficiency of power conversion.

The present invention solves the aforementioned problem by mounting apower breaker, a power conversion circuit, a rectifier circuit and avoltage conversion circuit in this order on a core frame constituting achassis of a battery charger.

According to the present invention, as lengths of cables among powerconversion components are made as equal as possible and flows ofrespective powers in a theoretical circuit and a real circuit of abattery charger are made substantially equal, efficiency of powerconversion can be improved.

BRIEF DESCRIPTION OF DRAWINGS

The description herein makes reference to the accompanying drawingswherein like reference numerals refer to like parts throughout theseveral views, and wherein:

FIG. 1 is a circuit diagram depicting a charger system to which anembodiment of the present invention is applied.

FIG. 2 is a block diagram depicting components constituting the chargerdevice of FIG. 1 and flow of electric power therein.

FIG. 3 is a drawing showing a mounting structure of a power conversiondevice constituting the charger device of FIG. 2 onto a core frame.

FIG. 4 is a total perspective view showing a chassis of the chargerdevice according to the embodiment of the present invention.

FIG. 5 is a perspective view in which the chassis of FIG. 4 is brokenand shown.

FIG. 6 is a sectional view taken along a line VI-VI of FIG. 4.

FIG. 7 is an exploded perspective view in which an outer housing of FIG.5 is viewed from its back.

FIG. 8 is a perspective view enlarging and showing a part VIII of FIG.5.

FIG. 9 is a perspective view enlarging and showing a part IX of FIG. 5.

FIG. 10 is a perspective view showing a state where heat sinks aremounted on the core frame of FIG. 5.

FIG. 11A is a perspective view showing a state where the powerconversion device is mounted on the core frame of FIG. 5, which isviewed from the front.

FIG. 11B is a perspective view showing the state where the powerconversion device is mounted on the core frame of FIG. 5, which isviewed from the back.

FIG. 12 is a sectional view taken along a line XII-XII of FIG. 6.

DESCRIPTION OF EMBODIMENTS <<Outline of the Charger System 1>>

An outline of a charger system to which an embodiment of the presentinvention is applied will be first described hereinafter with referenceto FIG. 1. The charger system 1 of this example is to be applied to acase where a secondary battery 6 loaded on an electric vehicle or ahybrid vehicle is charged and is a system in which a power conversioncircuit 3 directly converts three-phase current power supplied from athree-phase current power source 2 into single-phase current power whicha transformer 4 properly boosts or steps down and thereafter a rectifier5 converts the power into a direct current power to charge the secondarybattery 6. In the meantime, 7 represents a smoothing circuit, 11represents a power breaker for switching the three-phase current powersource 2 on and off, and 12 represents a charging gun.

In the charger system 1 of the present example, on respective outputlines corresponding to respective phases (R-phase, S-phase, T-phase) towhich three-phase current power is supplied from the three-phase currentpower source 2, a filter circuit 8 for reducing harmonics, as a measureagainst noise, is provided. The filter circuit 8 of the present exampleis constituted of three filter reactors 81 respectively connected to therespective phases R,S,T and six filter capacitors 82L,82R connectedamong the respective phases R,S,T. The filter capacitors 82L,82R are forexample constituted of six filter capacitors.

In the charger system 1 of the present example, the three-phase currentpower is supplied via the filter circuit 8 to the power conversioncircuit 3, and is there converted into single-phase current power. Thepower conversion circuit 3 of the present example is comprised of sixbidirectional switching devices 31 (311-316) arranged in a matrix-likearrangement corresponding to the R-phase, S-phase, T-phase, and is alsoreferred to as a matrix converter. While the reference sign 31 will bereferred hereinafter when a single bidirectional switching device iscollectively called, the reference signs 311-316 will be referred when aparticular device selected from the six bidirectional switching devicesis called.

Each of the bidirectional switching devices 31 is constituted of an IGBTmodule in which an IGBT as a semiconductor switching device is combinedwith and connected in antiparallel with a flywheel diode. In themeantime, the constitution of each bidirectional switching device 31 isnot limited to what is shown in the drawings and may be of any differentconstitution where two reverse blocking IGBTs are connected inantiparallel for example.

To each bidirectional switching device 31, for the purpose of protectingthe bidirectional switching device 31 from surge voltage generated inresponse to ON/OFF actions of the concerned bidirectional switchingdevice 31, a snubber circuit 32 (321-326) is provided at its input sideand its output side, in which one snubber capacitor 327 (see the circuitdiagram shown at the lower right in the same drawing) and three diodesare combined. While the reference sign 321 will be referred hereinafterwhen a single snubber circuit is collectively called, the referencesigns 321-326 will be referred when a particular snubber circuitselected from the six snubber circuits is called.

The charger system 1 of the present example is comprised of a matrixconverter control circuit 9 for ON/OFF control of the respectivebidirectional switching devices 31 of the power conversion circuit 3.The matrix converter control circuit 9 inputs a value of voltagesupplied from the three-phase current power source 2, a value of directcurrent being currently output, and a target current instruction value,based thereon controls respective gate signals of the bidirectionalswitching devices 31, and controls single-phase current power output tothe transformer 4 to obtain direct current power consistent with thetarget.

The transformer 4 boosts or steps down voltage of the single-phasecurrent power converted by the power conversion circuit 3 to apredetermined value. The rectifier 5 is comprised of four rectifierdiodes 51-54 for example to convert the voltage-controlled single-phasecurrent power into direct current power. Further the smoothing circuit 7is comprised of an inductor 71 and a capacitor 72 to smooth and bringpulsating current contained in the rectified direct current and therebybring it into a condition closer to direct current. The charging gun 12connects the direct current smoothed by the smoothing circuit 7 with acharging inlet of a vehicle (not shown) and therefrom supplies electricpower.

By the charger system 1 of the present example as constituted in a wayas described above, as shown in FIG. 2, the three-phase current powersupplied from the three-phase current power source 2 is supplied via thepower breaker 11 and the filter reactors 81 to the power conversioncircuit 3 and is, as the matrix converter control circuit 9 controls thepower conversion circuit 3, converted directly into the single-phasecurrent power, and is further controlled up or down to a proper voltageby the transformer 4 and thereafter converted into the direct currentpower by the rectifier 5. Further the direct current power smoothed bythe smoothing circuit 7 is supplied via the charging gun 12 to thesecondary battery 6, thereby charging the secondary battery 6. Meanwhilethe charger system 1 as described above is merely an example and thecharger system 1A according to the present invention is not limited tothe charger system 1 of the constitution as shown in the drawing.

<<Arrangement of Components of Charger Device>>

Next an arrangement and a constitution of the charger device 1Aincluding the power breaker 11 through the charging gun 12 of FIG. 2will be described hereinafter with reference to FIGS. 3-12. It is notedthat correspondence will be shown by attaching identical reference signsto components identical to those shown in FIGS. 1 and 2.

The charger device 1A of the present example is so constituted thatinside the chassis 13 mounted are the power breaker 11, the filterreactors 81, the power conversion circuit 3, the matrix convertercontrol circuit 9, the transformer 4, the rectifier 5 and the smoothingcircuit 7 shown in FIG. 2, and from the chassis 13 led out is the cable12 a, on a tip of which the charging gun 12 is mounted. The componentsmounted in the chassis 13 will be also referred to as power conversioncomponents.

Regarding the chassis 13, its bottom portion 141 is fixed to aninstallation spot of the concerned charger device 1A and it is comprisedof a core frame 14 on which the aforementioned power conversioncomponents are mounted, and an outer housing 15 mounted on and pinchingboth sides of the core frame 14. Meanwhile, “both sides” of the coreframe 14 mean the front and the back in the example shown in thedrawings and it is defined that the front is where a user gets accesswhen the charger device 1A is set and the back is opposed thereto. Theessential matter in the present invention is to mount the outer housing15 so as to pinch the core frame 14 and therefore the both sides are notlimited to the front and the back and may be left and right side faces.

The core frame 14 includes a base plate 141 constituting the bottomportion fixed to the installation spot of the charger device 1A by meansof any fixation means such as anchor bolts, and a core frame body 142bent in a C-letter shape in horizontal cross-section, and the core framebody 142 is as shown in FIG. 5 fixed to the base plate 141. A state ofthe horizontal cross section of the core frame body 142 is shown in FIG.6, the base plate 141 is shown in FIG. 8, and a top portion of the coreframe body 142 is shown in FIG. 9.

As shown in FIG. 8, the base plate 141 includes a base plate body 141 afixed to the installation spot by means of anchor bolts or such, and abracket 141 b fixed to the base plate body 141 a by means of welding,and the core frame body 142 is fixed to the bracket 141 b by means ofbolts or such. The core frame body 142 thereby stands upright and issecurely fixed to the installation spot. In the meantime, as shown inFIG. 9, at the top portion of the core frame body 142 provided is a pipe143 so as to penetrate it and at the both ends provided are suspensionharnesses 144. As the core frame 14 with the power conversion componentsmounted thereon, as described later, comes to be a heavy load, thesuspension harnesses 144 can be useful in work of installation byhooking it to a crane when the charger device 1A is to be transported tothe installation spot.

Returning to FIG. 5, the outer housing 15 includes a first outer housing15 a mounted on the front of the core frame 14 and a second outerhousing 15 b mounted on the back of the core frame 14. As shown in thesame drawing, the first outer housing 15 a of the present exampleincludes a side plate bent in a C-letter shape including a graduallycurved line in cross-section and a top plate, where the side plate andthe top plate are fixed together by means of welding or such. Further,as shown in FIG. 4, on the side plate at the front provided are anoperator's panel 151 for receiving input of operating instructions anddisplaying control states for example and a gun pocket 152 for housingthe charging gun 12 not in use.

The second outer housing 15 b of the present example is formed in a flatplate as shown in FIG. 5 and opened thereon are a through-hole 153 inwhich the power conversion circuit 3 and the rectifier 5 are mounted anda through-hole 154 for exposing heat sinks mounted on the powerconversion circuit 3 and the rectifier 5 out of the chassis. Further thefirst outer housing 15 a and the second outer housing 15 b are, as shownin FIG. 6, mounted on the core frame 14 by fixing these couplingportions together by bolts, screws or such as shown in FIG. 6.

In the meantime, although the first outer housing 15 a is formed in aC-letter shape in cross-section and the second outer housing 15 b isformed in a flat plate in this example, the outer housing 15 accordingto the present invention is not limited to such a shape and thereforeboth the components 15 a,15 b may be formed in a C-letter shape incross-section.

The outer housing 15 a is mounted on the core frame body 142 in such away as to be slidable by means of a rail structure. More specifically,as shown in FIG. 5, on both sides of the core frame body 142, at threespots thereof as being vertically apart, L-shape angle irons 145 arefixed, while on both internal sides of the first outer housing 15 a,likewise at three spots thereof as being vertically apart, L-shape angleirons 155 are fixed. These L-shape angle irons 145 of the core frame andthe L-shape angle irons 155 of the first outer housing mate together asshown in FIG. 12. The first outer housing 15 a is thereby made slidableforward and rearward relative to the core frame body 142, therebyimproving productivity in installation or un-installation of the firstouter housing 15 a.

In the meantime, as the pipe 143 to which suspension harnesses 144 aremounted as described above is provided so as to penetrate the firstouter housing 15 a and the core frame body 142, the outer housing 15 andthe core frame body 142 are thereby fixed together in both the verticaldirection and the fore-and-aft direction. On the other hand, when thepipe 143 is detached and the bolts or such fixing the first outerhousing 15 a with the second outer housing 15 b are detached, the firstouter housing 15 a or the second outer housing 15 b is readily detachedfrom the core frame body 142.

Next, descriptions about the power conversion components mounted on thecore frame body 142 will be given hereinafter. FIG. 3 shows a mountingstructure in a vertical cross section of the power conversion componentson the core frame body 142, FIG. 6 likewise shows the mounting structureof the power conversion components on the core frame body 142 in ahorizontal cross section, and FIG. 11A and FIG. 11B show a mountingstate of all the components.

As shown in FIG. 6 in horizontal cross-section, two rooms A,B lie insidethe chassis 13, which are partitioned by the core frame body 142. Morespecifically, they are two rooms of the room A confined by the C-lettercross section of the core frame body 142 and the room B at the backthereof. In this example, components producing heat are, when mounted inthe core frame body 142, mounted in the room A confined by the C-lettercross section. More specifically, as components producing heat among thepower conversion components shown in FIG. 2 are the power conversioncircuit 3, the rectifier 5 and the transformer 4, they are mounted atthe side of the room A. A fan 16 is at the same time mounted in thethrough-hole 153 opened on the second outer housing 15 b shown in FIG. 5so as to, as shown in FIG. 3, suck and introduce cooling air into theroom.

On the other hand, while the rest of the components of FIG. 2 can bemounted in the remaining space in the rooms A,B, these components arelaid out to run along flow of the electric power as far as possible whenthey are mounted in the core frame body 142. More specifically, if thepower breaker 11, the filter reactors 81, the power conversion circuit3, the matrix converter control circuit 9, the transformer 4, therectifier 5 and the smoothing circuit 7 can be arranged in this order,imbalance among the respective phases originated from inductances amonglines and noises will be suppressed, thereby improving power conversionefficiency.

Thus in this example, they are placed in a layout as shown in FIG. 3 andFIGS. 11A,11B. In brief, the three-phase current power source 2 such asa commercial power source is introduced through the base plate 141 ofthe core frame 14 and connected with the power breaker 11 mounted at theuppermost portion of the room A. Cables from the power breaker 11 areinserted through through-holes 146 (see FIG. 5) opened on the core framebody 142 and connected with the filter reactors 81 mounted at theuppermost portion of the room B.

Cables from the filter reactors 81 are similarly inserted through thethrough-holes 146 opened on the core frame body 142 and then connectedwith the power conversion circuit 3 mounted at the next stage to theroom A. At the room B at the back of the power conversion circuit 3, thematrix converter control circuit 9 is mounted, and control cables fromthe matrix converter control circuit 9 are inserted through thethrough-holes 146 opened on the core frame body 142 and connected withthe power conversion circuit 3.

Normally, the transformer 4 is preferably mounted at the next to thepower conversion circuit in the room A. As the transformer 4 is howevera heavy load and thus stability of the charger device 1A is thought muchof, the transformer 4 is mounted at the lowermost portion of the room A.Cables from the power conversion circuit 3 are accordingly connectedwith the transformer 4 at the lowermost portion of the room A and cablesfrom the transformer 4 are connected with the rectifier 5 mounted at thenext to the power conversion circuit 3 in the room A. And, cables fromthe rectifier 5 are inserted through the through-holes 146 opened on thecore frame 142 and connected with the smoothing circuit 7 mounted at thelowermost portion of the room B. Meanwhile the cable 12 a, on the tip ofwhich the charging gun 12 is mounted, is led out through a proper spotof the first outer housing 15 a to the exterior. FIG. 11A shows amounting state of the components with the core frame body 142 viewedfrom the front and FIG. 11B shows the same from the back.

FIG. 10 shows a state where the heat sinks 10 mounted with the powerconversion circuit 3 and the rectifier 5 are mounted on the flange ofthe core frame body 142. On the backs of the heat sinks 10, the powerconversion circuit 3 and the rectifier 5 are mounted. As the heat sinks10 are fixed with the flange of the core frame body 142 and thereby theheat sinks 10 with high rigidity come to be a structure constituting thecore frame body 142, rigidity of the core frame body 142 of itself isimproved.

The aforementioned embodiment produces the following effects.

1) In this example, because the chassis 13 of the charger device 1A isconstituted of a core frame body 142, in which the base plate 141 at itsbottom portion is fixed to the installation spot and the powerconversion components are mounted thereon, and the outer housings 15a,15 b detachably attached to the concerned core frame body 142 so as topinch both sides thereof, when the first outer housing 15 a is detachedfrom the core frame body 142, the filter reactors 81, one can make thematrix converter control circuit 9 or the smoothing circuit 7, any ofwhich are mounted in the room B, ready for maintenance or inspection asshown in FIG. 11A. Further, when the second outer housing 15 b isdetached from the core frame body 142, one can make the power breaker11, the power conversion circuit 3, the rectifier 5 or the transformer4, any of which are mounted in the room A, ready for maintenance orinspection as shown in FIG. 11B. The charger device 1A of this exampleis in this way superior in workability of maintenance or inspection,improves freedom of design in regard to the outer housing 15, and canmake the charger device 1A of itself compact.

2) In this example, because the first outer housing 15 and the coreframe body 142 are so constituted as to be slidable by means ofengagement of the L-shape angle irons 145,155, productivity of assemblyincluding positioning the first outer housing 15 a relative to the coreframe body 142 at a time of detaching and attaching is prominentlyimproved.

3) In this example, because the core frame body 142 is formed in aC-letter shape in horizontal cross-section and the power conversioncomponents are mounted on both sides thereof, its cumulation ratioincreases and in addition lengths of the cables connecting thecomponents can be shortened.

4) In this example, because the through-holes 146 are opened on the coreframe body 142 and the cables connecting the power conversion componentsare inserted therethrough, the lengths of the cables can be furthershortened.

5) In this example, the core frame body 142 is formed in a C-lettershape in cross-section, in the room A confined by the C-letter crosssection, the power conversion circuit 3, the transfer 4 and therectifier 5 producing heat are mounted, and cooling air is made to beintroduced into the room A by means of the fan 16. Although it ispossible without any means to prevent heated air from staying there asthe room A is confined by the C-letter cross section, in this example,as the fan 16 is provided, air introduced from the uppermost portion ofthe room A as shown in FIG. 3 flows down without diffusion through theroom A confined by the C-letter cross section of the core frame body 142toward the lower portion. It can thereby cool the components producingheat. Further, because the heat sinks 10 are provided on the powerconversion circuit 3 and the rectifier 5 particularly producingconsiderable heat and the heat sinks 10 are exposed out of the exteriorthrough the through-hole 154 of the second outer housing 15 b,efficiency of cooling is further improved.

6) In this example, because the power breaker 11, the power conversioncircuit 3, the rectifier 5 and the transformer 4 are arranged in thisorder, the lengths of the cables among the power conversion componentsare made as equal as possible, flows of the respective powers in atheoretical circuit of the charger device 1A shown in FIG. 2 and a realcircuit shown in FIG. 3 are made substantially equal. As a result,efficiency of power conversion can be improved.

The power breaker, the filter reactors 81, the power conversion circuit3, the matrix converter control circuit 9, the transformer 4, therectifier 5 and the smoothing circuit 7 as described above arecorresponding to the power conversion components in the presentinvention, the L-shape angle irons 145,155 are corresponding to a railstructure of the present invention, the transformer 4 is correspondingto a voltage conversion circuit of the present invention, and therectifier is corresponding to a rectifying circuit of the presentinvention.

1. A battery charger on which power conversion components for convertingcommercial power into direct current power are mounted, comprising:wherein the power conversion components include a power breaker forswitching input alternate current power ON/OFF, a power conversioncircuit for converting the input alternate current power into apredetermined alternate current power, a voltage conversion circuit forconverting the predetermined alternate current power into apredetermined voltage, and a rectifier circuit for converting alternatecurrent power converted into the predetermined voltage; a core frame onwhich the power conversion components are mounted; and an outer housingso attached to the core frame as to cover the core frame, wherein thepower breaker, the power conversion circuit, the rectifier circuit, andthe voltage conversion circuit are mounted in this order from an upperportion to a lower portion of the core frame.
 2. The battery charger ofclaim 1, wherein the core frame is formed in a C-letter shape inhorizontal cross-section, and the power conversion components aremounted on both sides thereof respectively.
 3. The battery charger ofclaim 2, wherein the power conversion circuit, the voltage conversioncircuit and the rectifier circuit are mounted on one side of the coreframe, and the power breaker is mounted on another side of the coreframe.
 4. The battery charger of claim 3, wherein the power conversioncomponents further include a filter circuit, a smoothing circuit and apower conversion circuit control circuit, and the filter circuit, thesmoothing circuit and the power conversion circuit control circuit aremounted on the other side of the core frame.
 5. The battery charger ofclaim 1, wherein a through-hole having a cable for connecting the powerconversion components inserted through is formed on the core frame.